Conversion of Wellhead Platform to Production Platform
Challenge
An independent oil company faced a 20MBPD production deferment due to a failed sealine between
its offshore wellhead platform and FPSO in the Gulf of Guinea. The idea of installing an EPF on the
existing platform was proposed, and ZETA was asked to evaluate it.
Our approach
We assessed structural, technical safety, process, and control aspects. Through qualitative
and quantitative analyses, we determined whether the new equipment would unacceptably
impact safety or production performance.
Our engineers built numerical models for each feasible layout to conduct sensitivity analyses,
avoiding the impracticalities of testing under extreme pressure, force, and temperature.
With the numerical model, we were able to
vigorously analyse key aspects of each credible
layout option, deeply evaluating the structural
and naval architecture aspects (load-bearing
capacity, static loads, dynamic forces, forces
from operating scenarios, FEA-determined
stress and strain distribution, cyclic loading and
fatigue, stability and buoyancy, metacentric
changes, etc.) material metallurgy aspects
(potential corrosion and wear), technical
safety aspects (fire and explosion risk,
hazardous area classification, mitigation
systems, active and passive fire protection,
emergency response, evacuation routes,
safety drills register updating, MOPO analysis
and design reviews, etc.) process aspects
(H&MB, process flow analysis, interfacing
equipment, equipment compatibility and integration, efficiency and process optimization, new process bottlenecks, etc), control and communication aspects (automation and
control, integration, seamless operation and monitoring, criticality mapping, reliability, availability,
redundancy, protection and fail-safe mechanisms, backup systems, communication protocols, etc.),
environmental aspects (new environmental impacts, regulatory compliance, operational impact, etc.),
maintenance aspects (longevity and reliability, MTTM, etc.), and more.
Results
We were able to generate an outline of possibilities, the potential impact of the platform conversion,
necessary mitigations, and reinforcements, all supported quantitatively. Armed with the outcome of
our quantitative analyses, the client was able to reach a decision underpinned by solid numbers.
